Low-Torque Valve and Assemblies Including Said Valve

ABSTRACT

A low-torque valve for regulating fluid flow between a valve inlet and a valve outlet is disclosed. The low-torque valve has a stationary valve element and a rotatable valve element. The stationary valve element and the rotatable valve element each may have a respective axially-facing mating surface in contact with each other. At least one opening in the rotatable valve element is rotationally positionable with respect to at least one opening in the stationary valve element between an open position and a closed position in order to regulate fluid flow from the valve inlet to the valve outlet based on an alignment of the openings of the stationary valve element and the rotatable valve element. In some forms, a torque threshold that is required to rotate the rotatable valve element into the open position from the closed position is less than 10 ounce-inches.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication No. 62/399,807 filed on Sep. 26, 2016, the contents of whichare incorporated by reference for all purposes as if set forth in theirentirety herein.

STATEMENT OF FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

FIELD OF INVENTION

This disclosure relates to a low-torque valve and the operation thereof.

BACKGROUND

Motor-driven valves are known for the automated operation of valves inmany applications. Typically, a power source, such as mains power or abattery, selectively drives the motor to open or close the valve in thepresence of some condition (e.g., a controller receives a signal that acondition has been met and the motor is driven to a particular positionto alter the state of the valve).

In many applications, installation of mains electricity to themotor-driven valve can be quite expensive, especially where mains poweris not currently run to the physical location at which the motor-drivenvalve is to be used. In such situations, the cost of running mains powerto the location versus the cost of consumable battery usage andmaintenance must be weighed against one another and further must becompared against the design consideration of not implementing amotor-driven valve at all.

Unfortunately, in those situations, limited battery life provides a hardconstraint on the convenience of and/or the ability to use suchmotor-driven valves when mains power is not a viable option. Forexample, in a battery-powered motor-driven valve, the valve will stopworking once the battery is consumed which effectively halts theoperation of the valve. Thus, it becomes essential to either routinelyreplace the batteries before they are consumed (which is highlyinefficient) or to provide just-in-time replacement of batteries whenthey are consumed. In either case, there are significant maintenancecosts associated with monitoring and replacing batteries.

Such maintenance and cost issues associated with batteries haveprevented wider adoption of battery-driven motor-driven valves forapplications when use of mains power is not a viable option.

SUMMARY OF THE INVENTION

Proposed herein are various designs for a low-torque valve that requiresless power and torque to operate the valve which can thereby prolong theoperational life of a device implementing the valve between batterychanges are required. This can make the use of batteries in amotor-driven valve viable in contexts where it would be commerciallyunacceptable to need to replace batteries frequently (e.g., faucets,flush valves, and so forth). However, such low-torque valves could beequally powered by mains power.

According to one aspect, a low-torque valve for regulating fluid flowbetween a valve inlet and a valve outlet is disclosed. The low-torquevalve comprise a stationary valve element and a rotatable valve element.The stationary valve element and the rotatable valve element each mayhave a respective axially-facing mating surface in contact with eachother. The stationary valve element and the rotatable valve element alsoeach have at least one opening. The stationary valve element and therotatable valve element are rotationally positionable relative to oneanother between an open position and a closed position in order toregulate fluid flow from the valve inlet to the valve outlet based on analignment of the openings of the stationary valve element and therotatable valve element. A torque threshold to rotate the rotatablevalve element into the open position from the closed position is lessthan 10 ounce-inches.

In some forms, the low-torque valve may further have a valve housingthat has an internal chamber that receives the stationary valve elementand the rotatable valve element. The internal chamber may have at leastone opening in a peripheral wall providing or defining the valve outlet.The low-torque valve may further have an O-ring seal dimensioned to bereceived around the valve housing configured to form a seal between thevalve housing and a structure into which the valve housing is adaptedfor reception.

In some forms, the opening(s) in the peripheral wall of the valvehousing may extend in a radial direction to accommodate fluid flow in aU-shaped manner up (i.e., one in which the water flows in one directionand then is re-directed, at least in part, in a direction roughlyparallel and opposite to that direction) through the valve elements ofthe low-torque valve, radially out the opening(s) in the peripheral wallto bend the flow, and down between an outer radial wall of the valvehousing and a structure into which the valve housing is adapted forreception.

In some forms, the respective axially-facing mating surfaces of thestationary valve element and the rotatable valve element may contacteach other to form a dynamic seal therebetween.

In some forms, a total torque threshold that may be required to completea valve cycle may be less than 12 ounce-inches. The valve cycle includesthe rotatable valve element being moved from the closed position to theopen position and then back to another, different closed position in asingle direction of rotation of the rotatable valve element.

In some forms, the opening(s) in the stationary valve includes an inletopening and an outlet opening in which the inlet opening is in constantfluid communication with the valve inlet and the outlet opening is inconstant fluid communication with the valve outlet.

In some forms, the rotatable valve element may have a patterned recesson the axially-facing mating surface for selectively placing the inletopening and the outlet opening in fluid communication with one anotherbased on a rotational position of the rotatable valve element relativeto the stationary valve element. In the open position, the inlet openingand the outlet opening may be placed in fluid communication with oneanother by the patterned recess such that the valve inlet to the valveoutlet are placed in fluid communication with one another. The patternedrecess may, in some forms, include a plurality of channels outwardlyextending from a centrally-connected location with the plurality ofchannels being in fluid communication with one another at thecentrally-connected location. The patterned recess may, in some forms,be rotationally symmetrical about a central axis of the rotatable valveelement.

In some forms, only small angular adjustments of the rotatable valveelement may be necessary to go from a closed to an open to a closedposition. For example, the inlet openings and the outlet openings may beselectively aligned at 45 or, alternatively, 60 degree incrementedpositions of the rotatable valve element. For example, in the case of apatterned recess, the movement of the valve from the closed position toan open position may occur over 45 degrees of clockwise rotation of therotatable valve element, and a further 45 degrees of clockwise rotationof the rotatable valve element may move the valve from the open positionback into a closed position. Thus, over a single continuous arc 360degrees of motion in one direction, such a valve may be closed andopened four times. Likewise, at 60 degree increments, the valve may beopened and closed three times. This design helps to reduce traveldistance between the open and closed positions, which reduced the energyrequired to activate the valve and, according, reduces power consumptionand prolongs the operational life with a fixed amount of available power(as is the case when batteries are used).

In some forms, in the open position, there may be two points ofcommunication at the axially-facing mating surfaces between thepatterned recess in the rotatable valve element and a pair of openingsin the stationary valve element.

The total torque threshold to complete a valve cycle may be dependent onthe particular low torque design employed. In some forms, a total torquethreshold required to complete a valve cycle is less than 19ounce-inches. In some forms, a total torque per a valve cycle thresholdis less than 9 ounce-inches. In some forms, an outer diameter of thestationary valve element and the rotatable valve element may be lessthan 0.5 inches.

In some forms, the rotatable valve element and the stationary valveelement may comprise a ceramic material.

According to another aspect, a flush valve assembly is provided. Theflush valve assembly includes a fluid passageway between an assemblyinlet and an assembly outlet, a chamber positioned along the fluidpassageway, and a low-torque valve according to any of the previousaspects. The diaphragm assembly is positioned in the chamber andbifurcate the chamber into an upper chamber and a lower chamber. Thediaphragm assembly has a diaphragm having a bypass opening that placesthe upper chamber and the lower chamber in fluid communication with oneanother.

The diaphragm assembly is selectively received at a diaphragm seat toregulate flow between the assembly inlet and the assembly outlet duringa flush cycle by controlling fluid communication between the lowerchamber and an outlet chamber that connects the lower chamber to theassembly outlet. The low-torque valve is operable as a pilot valve tocontrol a flush cycle by placing the upper chamber and the outletchamber in selective fluid communication with one another. When thelow-torque valve is in the open position, a fluid pressure from theupper chamber may be released through the low-torque valve to unseat thediaphragm assembly from the diaphragm seat to initiate the flush cycle.When the low-torque valve in the closed position, the diaphragm assemblymay re-seat on the diaphragm seat due to an increased fluid pressure onthe diaphragm assembly from the upper chamber to end the flush cycle.

In some forms, the low-torque valve may be axially offset from an axisof the assembly outlet.

In some forms, a rotational axis of the low-torque valve is orientedtransverse to the assembly outlet.

In some forms, the valve changes the direction of fluid flow within thevalve itself.

In some forms, a power source may be connected to a motor, the motorproviding rotational control to the rotatable valve element toselectively rotate the rotatable valve element into an open position inwhich the at least one opening in the rotatable valve element alignswith the at least one opening in the stationary valve element therebyproviding fluid communication therebetween. Although it is contemplatedthat mains power could power the motor, it is contemplated that anelectrochemical device or battery could be this power source and—in sucha power-constrained or power-limited scenario—the low torque valvedesign may provide exceptional benefit because it improves the length oftime the valve can be operated using the battery (or set of batteries),before requiring replacement due to reduced power consumption peroperational cycle.

Although the use of a valve assembly is described, it should beappreciated that the valve assembly is not limited to use in a flushvalve assembly or in a relief valve assembly. The valve assembliesdisclosed herein can have a wide variety of implementations. Somenon-limiting examples of implementations of the valve assembliesdisclosed may include faucets, mixing valves, flush valves, showerapplications, plumbing fixtures, and non-plumbing fixtures andapplications.

In yet another more specific aspect, a low-torque ceramic valve forregulating fluid flow between a valve inlet and a valve outlet isdisclosed. The low-torque valve may comprise a stationary disc valveelement, a rotatable disc valve element, a valve housing, and an O-ringseal. The stationary disc valve element and the rotatable disc valveelement may be positioned along a valve axis and each having arespective axially-facing mating surface in contact with each other, therespective axially-facing mating surfaces of the stationary disc valveelement and the rotatable disc valve element contact each other to forma dynamic seal therebetween that prevents fluid communication external aflow path through the valve. The stationary disc valve element and therotatable disc valve element each may have at least one opening in whichthe stationary disc valve element and the rotatable disc valve elementare rotationally positionable relative to one another between an openposition and a closed position in order to regulate fluid flow. Thevalve housing may have an internal chamber that receives the stationaryvalve element and the rotatable valve element, the internal chamberhaving at least one opening in a peripheral wall, the at least oneopening in the peripheral wall of the internal chamber provides fluidcommunication between the rotatable valve element and the valve outlet.The O-ring seal dimensioned to be received around the valve housing anddimensioned to prevent fluid communication external to a flow paththrough the valve. A torque threshold to rotate the rotatable valveelement into the open position from the closed position may be less than10 ounce-inches.

These and still other advantages of the invention will be apparent fromthe detailed description and drawings. What follows is merely adescription of some preferred embodiments of the present invention. Toassess the full scope of the invention, the claims should be looked toas these preferred embodiments are not intended to be the onlyembodiments within the scope of the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a sectional view of a relief valve in a flush valve assembly.

FIG. 2 is an exploded view of the flush valve assembly of FIG. 1.

FIG. 3 is a perspective view of a relief valve housing.

FIG. 4 is a sectional view of the relief valve from area 4-4 of FIG. 1.

FIG. 5 is an exploded view of the relief valve.

FIG. 6 is a sectional view of an area A-A from FIG. 1 of the flush valvein the closed position.

FIG. 7 is a sectional view of an area A-A of the flush valve just aftera relief valve is opened.

FIG. 8 is a sectional view of an area A-A of the flush valve in the openposition.

FIG. 9 shows relief valve results of torque in ounce inches versus waterpressure.

FIG. 10 is a sectional view of a relief valve positioned in a flushvalve assembly.

FIG. 11 is an exploded view of a relief valve and an assembly frame.

FIG. 12A is an exploded view of a relief valve that can be received inthe assembly frame of FIG. 11.

FIG. 12B is a top exploded view of relief valve elements of FIG. 12A.

FIG. 13 shows relief valve results of torque in ounce inches versuswater pressure for the relief valve of FIG. 12A.

FIG. 14 is an exploded view of a relief valve that can be received inthe upper housing of FIG. 11.

FIG. 15 is a top exploded view of relief valve elements of FIG. 14.

FIG. 16 shows relief valve results of torque in ounce inches versuswater pressure for the relief valve of FIGS. 14 and 15.

FIG. 17 is a sectional view of a valve positioned in a flush valveassembly.

FIG. 18 is an exploded view of a valve that can be received in flushvalve of FIG. 17.

FIG. 19 is an exploded view of the flush valve of FIG. 17.

FIG. 20 shows valve results of torque in ounce inches versus waterpressure for the valve of FIGS. 17-19.

DETAILED DESCRIPTION

Embodiments of the disclosure may be further understood with referenceto the figures.

FIGS. 1 and 2 illustrate one exemplary embodiment of a flush valveassembly 20. Although a flush valve assembly is shown, it is to beappreciated that the disclosure is not limited to flush valves, flushingmechanisms, or the like.

The flush valve assembly 20 has a housing that includes an upper housingbody 22 and a lower housing body 24 that may be connected such that theupper housing body 22 and lower housing body 24 enclose the flush valveassembly 20. In a non-limiting example, the upper housing body 22 may bethreaded into connection with the lower housing body 24. The lowerhousing body 24 may have an inlet 28, an outlet 32, and a cap over anopening 34 that would traditionally accommodate a mechanical flushlever. The inlet 28 to the lower housing body 24 may connect the lowerhousing body 24 to a fluid source and provide fluid communicationtherebetween. The inlet 28 may be secured to a fluid source via a nut 36that circumferentially extends around an inlet extension 40, an O-ring46, and a locking ring 48. The inlet extension 40 may be cylindrical inshape and defines a hollow inner chamber 42 for the passage of water.The lower housing body 24 receives the inlet extension 40, which extendsperpendicularly outward from the lower housing body 24. The connectionof the inlet extension 40 and the lower housing body 24 connects theinner chamber 42 of the inlet extension to a lower chamber 44 within thelower housing body 24. The lower chamber 44 of the housingcircumferentially surrounds a valve seat 84.

A diaphragm assembly 52 is disposed within the upper housing body 22 andthe lower housing body 24 between the inlet 28 and the outlet 32 andincludes a diaphragm 56 and a disc 60. The diaphragm assembly 52positioned in a chamber and bifurcating the chamber into an upperchamber 88 and the lower chamber 44. The diaphragm assembly 52 has adiaphragm assembly opening 64 and a bypass opening 68. As illustrated,the diaphragm assembly opening 64 is centrally located on the diaphragmassembly 52 and the bypass opening 68 may be peripherally located on thediaphragm assembly 52; however, they may be otherwise geometricallydisposed. The diaphragm 56 and the disc 60 extend circumferentiallyoutward, each defining an outer diameter. The outer diameter of thediaphragm 56 is larger than the outer diameter of the disc 60. The disc60 is received in a central opening in the diaphragm 56 that aligns withthe opening 64 in the diaphragm assembly 52. The diaphragm 56 receives abase end 72 of the disc 60 in the central opening in the diaphragm 56while an outward protrusion 76 of the disc 60 is disposed above aportion of a top surface of the diaphragm 56. The base 72 of the disc 60is threadably connected to a cylinder guide 80.

A bottom surface of the outward protrusion 76 of the disc 60 may befixed to a top surface of the diaphragm 56. The outward protrusion 76 ofthe disc 60 has a raised inner area 164 that has a thickness greaterthan the thickness of the outward protrusion 76. The disc 60 surrounds alower body 128 of a bypass extension 122 of the assembly frame 96 thatis centrally positioned through the diaphragm assembly 52. The bypassextension 122 extends through the upper chamber 88 into the diaphragmassembly 52.

The cylinder guide 80 is positioned below the diaphragm 56 and the disc60 and is cylindrical. The cylinder guide 80 defines a peripheralchamber 82 between an outer wall of the cylinder guide 80 and an innerwall of the valve seat 84 that extends upward in the housing as acylindrical column.

The cylinder guide 80 extends below the diaphragm 56 and features adiaphragm assembly extension upper support 244 and one or more diaphragmassembly extension lower supports 248. A bottom surface of the diaphragmassembly extension upper support 244 is fixed to a top surface of one ormore diaphragm assembly extension lower supports 248. The diaphragmassembly extension upper support 244 is cylindrical in shape and wrapsaround the cylinder guide 80 while leaving a gap 246 around an outersurface of the cylinder guide 80. The one or more diaphragm assemblylower supports 248 are rectangular and are positioned vertically on theouter surface of the cylinder guide 80. The one or more diaphragmassembly lower supports 248 are spaced radially around the perimeter ofthe cylinder guide 80. The one or more diaphragm assembly lower supports248 may be placed at 90 degree intervals around an outer surface of thecylinder guide 80.

The diaphragm assembly 52 contacts a top surface of the valve seat 84and the cylinder guide 80 extends into the lower housing body 24. Whenthe flush valve assembly 20 is in the closed position as is illustratedin FIG. 1, the diaphragm assembly 52 is positioned on a top lip of thevalve seat 84 which places the diaphragm assembly 52 in a sealingposition between the inlet 28 and the outlet 32. An upper chamber 88 ispositioned above the diaphragm assembly 52 and is in fluid communicationwith the lower chamber 44 via the bypass opening 68 of the diaphragm 56.

A relief valve assembly 92 is positioned within and supported by anassembly frame 96 that is secured between the upper housing body 22 andlower housing body 24. The relief valve assembly 92 may be offset froman outlet passageway 132 of the flush valve assembly 20. An innersurface of the assembly frame 96 may also provide a top wall of theupper chamber 88 that provides a fluid boundary that prevents fluid fromcommunicating outside of the assembly frame 96. Fluid communication isprovided to the relief valve assembly 92 from the upper chamber 88 viaan inlet opening 134 in the assembly frame 96.

The relief valve assembly 92 includes a motor 100 connected to a powersource 102 positioned outside of the assembly frame 96. In anon-limiting example, the power source 102 may be one or more batteries.The motor 100 has a shaft 104 that extends out of the motor 100 andconnects to a driving member 108. The driving member 108 is connected toa rotatable valve element 112 that is positioned below the drivingmember 108 and the shaft 104. The rotatable valve element 112 ispositioned above a stationary valve element 116 (both of which are inthe shape of discs). Illustratively, it should be appreciated that therotatable valve element 112, which is shown in greater detail in FIGS.3-5 and discussed more below, may be a moveable valve element and/or atranslatable valve element. A relief valve housing 120 receives thedriving member 108, the rotatable valve element 112, and the stationaryvalve element 116.

The relief valve assembly 92 may be received within the upper housingbody 22. The motor 100 may be secured to the assembly frame 96 viascrews 216 fixed to a top surface of an upper body 228 of the assemblyframe 96. The upper body 228 of the assembly frame 96 may extendvertically from a lower body 232 of the assembly frame 96. The upperbody 228 of the assembly frame 96 may be cylindrical having a hollowinner chamber configured to receive an O-ring 236 and the relief valvehousing 120. The lower body 232 of the assembly frame 96 may extendradially outward from a bottom surface of the upper body 228 of theassembly frame 96.

The relief valve assembly 92 is positioned above the diaphragm assembly52 within the upper housing body 22.

In some embodiments, the flush valve assembly 20 may further include amanual actuation assembly 140 received in the assembly frame 96. Themanual actuation assembly 140 can include an actuation interface 144 andan actuation member 148. The actuation interface 144 may extend outsideof the upper housing body 22 and may be linked to the actuation member148. The actuation member 148 may be fixed to the actuation interface144 and may extend to the top wall of the upper chamber 88 to provide amanual override to the relief valve assembly.

The upper housing body 22 has a sensor opening 188 and which may be anyappropriate shape. As shown in a non-limiting example, the sensoropening 188 may be rectangular with rounded edges oriented vertically onthe upper housing body 22. The sensor opening 188 may be any appropriateshape to receive a sensor that that may be positioned within the upperhousing body 22 or to permit the sensor to sense therethrough. In theform illustrated, the upper housing body 22 is configured to contain thediaphragm assembly 52, the relief valve assembly 92, the power source102 and a sensor.

Referring now to FIGS. 3-5, the relief valve assembly 92 may beassembled with the shaft 104 of the motor 100 extending into the drivingmember 108. In some embodiments, a bottom surface of the shaft 104 maybe fixed to a top surface of the driving member 108. In otherembodiments, the shaft 104 and the driving member 108 may be connectedby a keyed connection, D-shape connection, geared connection, or anyother suitable connection between a motor shaft and a driving member. AnO-ring 264 is positioned between driving member ring 252 that extendsradially outward from a driving member body 256. The driving member body256 may be cylindrical in shape and may receive the O-ring 264 around anouter surface of the driving member body 256 below the driving memberring 252. A driving member arm 254 is rectangular in shape and hasrounded ends and extends along the bottom surface of the driving memberbody 256. A friction washer (not shown) having, for example, the shapeof a flat disc with a central opening can be positioned between therelief valve housing 120 and the driving member ring 252, the frictionwasher reducing friction between the driving member ring 252 and therelief valve housing 120.

The driving member arm 254 is received within one or more rotatablevalve element walls 260 that extend vertically from the rotatable valveelement 112. A top surface of the rotatable valve element 112 has ashape that is concave up thereby recessing away from the driving memberarm 254. The driving member arm 254 has a length that allows the drivingmember arm 254 to be received within the rotatable valve element walls260. The rotatable valve element walls 260 extend vertically from thetop surface of the rotatable valve element 112. The rotatable valveelement walls 260 are positioned in order to receive the driving memberarm 254 in a gap in each of the rotatable valve element walls 260.

The rotatable valve element 112 may be a rotatable disc valve elementthat may have openings 272 through the rotatable valve element 112 thatselectively align with one or more openings 276 in the stationary valveelement 116. The openings 272 of the rotatable valve element 112 may bepositioned opposite each other, each having a tapered oblong shape thatwidens towards an exterior portion of the rotatable valve element 112.Put another way, the openings 272 may have a tear-drop shape that iswider near an exterior portion of the rotatable valve element 112. Asillustrated, there may be two openings 272 in the rotatable valveelement positioned at 180 degrees from each other through the rotatablevalve element 112. A bottom surface profile 274 may be cut into thebottom surface of the rotatable valve element 112, the bottom surfaceprofile 274 may have two semi-circular regions connected by a narrowedcentral portion positioned between the openings 272. Among other things,the large amount of recessed surface or absent surface (especially thatformed by the recessed bottom surface profile 274) reduces the overallsurfaces area of bearing between the valve elements, which can helpminimize the friction required to turn the elements with respect to oneanother.

As illustrated, the openings 276 in the stationary valve element 116have a tapered oblong shape that widens towards an exterior portion ofthe stationary valve element 116 and sized to match or approximatelymatch the size and/or shape of the openings 272 in the rotatable valveelement 112. Put another way, the openings 276 may have a tear-dropshape that is wider near an exterior portion of the stationary valveelement 116. In one example, there may be four openings 276 through thestationary valve element 116, even though, by design only two openings276 may have active flow through them at a given moment in time. Theopenings 276 may be cut normally through a top and bottom surface of thestationary valve element 116. The openings 276 are oriented at orapproximately 90 degrees apart such that the openings 276 aresymmetrical about a relief valve axis 126 across the stationary valveelement 116. The stationary valve element 116 may be a stationary discvalve element that has a cylindrical shape with the openings 276 cuttherethrough. The stationary valve element 116 has tabs 292 extendingfrom the outer surface that are configured to secure the stationaryvalve element 116 in a rotationally fixed position.

The stationary valve element 116 has a mating surface 280 that isaxially-facing and mates with a mating surface 282 of the rotatablevalve element 112, the respective axially-facing mating surfaces 280,282 are in contact with each other. The mating surfaces 280, 282 of thestationary valve element 116 and the rotatable valve element 112 contacteach other to form a dynamic seal therebetween that prevents fluidcommunication external a flow path through the relief valve assembly 92.

An inlet gasket 220 of the relief valve assembly 92 is positioned belowthe stationary valve element 116 within the relief valve housing 120.Fluid communication is provided to the relief valve assembly 92 from theupper chamber 88 via an inlet opening 134 in the assembly frame 96 andthrough the inlet gasket 220. The inlet gasket 220 provides a reduceddiameter of fluid communication from the inlet opening 134 to thestationary valve element 116. The inlet gasket 220 provides compressiveforces to ensure the rotatable valve element 112 and the stationaryvalve element 116 remain in contact with one another creating a fluidtight seal.

The relief valve housing 120 receives the driving member 108, therotatable valve element 112, the stationary valve element 116, and theO-ring 264. A portion of the relief valve housing 120 has an outersurface 124 which may be fixed within the assembly frame 96 to securethe relief valve housing 120 to the assembly frame 96. The outer surface124 is positioned below an upper extension 268 of the relief valvehousing 120. The upper extension 268 extends radially outward from therelief valve housing 120 and has two flattened surfaces 270 positionedon opposing sides of the upper extension 268. Below the outer surface124 of the relief valve housing are two peripheral openings 266 in therelief valve housing 120. The peripheral openings 266 extend in a radialdirection around the relief valve housing 120 and providing the reliefvalve outlet. The O-ring 236 may be received around the relief valvehousing 120 between the outer surface 124 and the upper extension 268.The O-ring 236 is dimensioned to be received around the relief valvehousing 120 and configured to form a seal between the relief valvehousing 120 and the assembly frame 96 into which the relief valvehousing 120 is adapted for reception.

The relief valve outlet at the peripheral openings 266 in the reliefvalve housing 120 provides selective fluid communication between therelief valve assembly 92 and a circumferential passageway 240 positionedaround the circumference of the relief valve housing 120 and between theassembly frame 96 and the relief valve housing 120. The circumferentialpassageway 240 is connected with an actuation passageway 242 definedbetween the circumferential passageway 240 and the manual overrideassembly 140 in the assembly frame 96. The actuation passageway 242 isin fluid communication with the outlet passageway 132 through the lowerbody 128 of the bypass extension 122 of the assembly frame 96. The lowerbody 128 of the bypass extension 122 is centrally positioned through thediaphragm assembly 52, which connects the actuation passageway 242 withthe outlet passageway 132.

Now that the components of the relief valve assembly 92 and the flushvalve assembly 20 have been described in detail, their respectivefunctionalities may be appreciated. Referring to FIGS. 3-5 the motor 100may be configured to generate rotational motion that is translated tothe shaft 104. Rotational motion of the shaft 104 translates rotationalmotion to the driving member 108 and, consequently, the driving memberarm 254. The driving member arm 254 received within the rotatable valveelement walls 260 causes rotation of the rotatable valve element 112.

Rotation of the rotatable valve element 112 may change the rotationalposition of the openings 272 of the rotatable valve element 112.Selective movement of the openings 272 through the rotatable valveelement 112 defines a plurality of positions of the relief valveassembly 92. A first position of the relief valve assembly 92 is an openposition defined by the openings 272 through the rotatable valve element112 aligning with an opposing pair of the openings 276 in the stationaryvalve element 116. Alignment of the openings 272 in the rotatable valveelement 112 with the openings 276 in the stationary valve element 116allows fluid communication through the relief valve assembly 92 in whichthe flow of fluid goes up the valve elements and radially out of theperipheral openings 266.

A second position of the relief valve assembly 92 is a closed positiondefined by the openings 272 through the rotatable valve element 112 notaligning with the openings 276 in the stationary valve element 116. Inthe closed position, the openings 276 in the stationary valve element116 are covered by rotatable valve element 112 such that the bottomsurface profile 274 places all of the openings 276 in communication withone another but not with the openings 272. Since the openings 276 in thestationary valve element 116 only serve as potential inlets, but do notflow unless they are in communication with the openings 272 of therotatable valve element 116, this rotational configuration of the discelements with respect to one another stops flow therethrough. Thus, inthe closed position, fluid communication is prohibited to pass throughthe relief valve assembly 92. Based on the illustrated geometry, theopened position and the closed position are approximately 45 degreesfrom one another, meaning that for every 90 degrees of rotation, thevalve can be moved from closed to open and back to closed. Given thenumber of openings this means a full 360 degrees of rotation will havefour full cycles of opening and closing associated with it.

Illustratively, the relief valve assembly 92 may include one or moremoveable and/or translatable valve elements. The one or more moveableand/or translatable valve elements may be selectively moved ortranslated with respect to one or more stationary valve elements.Movement of the one or more moveable and/or translatable valve elementsselectively provides fluid communication between the upper chamber 88and the outlet passageway 132.

Now with reference to FIGS. 6-8, the initiation of a flush cycle bytemporarily actuating the relief valve assembly 92 from the closedposition to the opened position is illustrated. The relief valveassembly 92 may generally function as a pilot valve to initiate a flushcycle as shown. This brief opening of the relief valve assembly 92 willcause the entire diaphragm assembly 52 to lift, permitting water totravel from the inlet 28 to the outlet 32.

FIG. 6 shows a detailed area A-A of the flush valve assembly 20 in aclosed position with fluid retained in the flush valve assembly 20 andis unable to enter the outlet chamber 136 because the diaphragm assembly52 remains sealed against the upper lip of the valve seat 84. Fluidprovided through the inlet 28 (not shown in FIG. 6, but found in priorfigures) into the inner chamber 42 which is in fluid communication withthe lower chamber 44. The lower chamber 44 surrounds outside wall thevalve seat 84 and is in fluid communication with the upper chamber 88via the bypass opening 68 in the diaphragm 56. The bypass opening 68places the lower chamber 44 in fluid communication with the upperchamber 88.

In the position illustrated in FIG. 6, the relief valve assembly 92 isin the closed position defined by the openings in the stationary valveelement 116 being covered by the rotatable valve element 112 therebypreventing fluid from flowing past the stationary valve element 116.Fluid communication is provided to the relief valve assembly 92 from theupper chamber 88 via an inlet opening 134 in the assembly frame 96 andthrough the inlet gasket 220.

As mentioned above, the diaphragm assembly 52 is in a closed positionwhile the relief valve assembly 92 is in the closed position. The closedposition of the diaphragm assembly 52 is defined by the diaphragmassembly 52 being received against the valve seat 84 creating a sealtherebetween. The diaphragm assembly 52 may be held in a closed positionby the force of fluid in the chamber 88, exerting a downward force onthe diaphragm 56 and the disc 60, thereby pressing the diaphragmassembly 52 against the valve seat 84.

FIG. 7 shows the area A-A of the flush valve assembly 20 just after therelief valve assembly 92 has been opened to initiate the opening of theflush valve assembly 20, but before water was passed entirely throughthe relief valve assembly 92 to permit the diaphragm assembly 52 tolift. The open position of the flush valve assembly 20 is achieved whenthe motor 100 selectively rotates the rotatable valve element 112 suchthat the openings in the rotatable valve element 112 align with theopenings in the stationary valve element 116 creating fluidcommunication through the relief valve assembly 92 such that water maypass from the upper chamber 88 into the outlet chamber 136.

The relief valve outlet at the peripheral openings 266 in the reliefvalve housing 120 is in fluid communication with the circumferentialpassageway 240 with the relief valve assembly 92 in the open position.The circumferential passageway 240 changes the direction of fluid flowin a U-shaped manner up through the stationary valve element 116 and therotatable valve element 112, radially out the peripheral openings 266 inthe peripheral wall of the relief valve housing 120 to bend the flow,and down into the circumferential passageway 240 between an outer radialwall of the relief valve housing 120 and the assembly frame 96. Thecircumferential passageway 240 is connected with the actuationpassageway 242 that is in fluid communication with the outlet passageway132 through the lower body 128 of the bypass extension 122 of theassembly frame 96.

Just after the relief valve assembly 92 has been opened, the diaphragmassembly 52 may briefly remain in the closed position. The diaphragmassembly 52 may remain in the closed position just after the reliefvalve assembly 92 opens because the pressure exerted on the diaphragmassembly 52 temporarily holds it on the valve seat 84 as the pressurehas not been relieved through the outlet chamber 136.

FIG. 8 shows the area A-A of the flush valve assembly 20 where therelief valve assembly 92 has remained opened and the diaphragm assembly52 has lifted such that the flush valve assembly 20 is in the openposition. The open position of the flush valve assembly 20 is achievedwhen the fluid from the upper chamber 88 is allowed to flow through theoutlet passageway 132 and into the outlet chamber 136 for a sufficientduration of time to break the seal at the valve seat 84. Fluid flowthrough the outlet passageway 132 into the outlet chamber 136 relievespressure in upper chamber 88 exerted on the diaphragm assembly 52. Underthis change in pressure, the diaphragm 56 is flexible in an upwarddirection and causes vertical translation of the diaphragm assembly 52away from the valve seat 84 to break the seal. Vertical translation ofthe diaphragm assembly 52 away from the valve seat 84 provides directfluid communication between the lower chamber 44 and the outlet chamber136 via the peripheral chamber 82. Put another way, with the diaphragmassembly 52 unseated from the valve seat 84, the inlet 28 and the outlet32 are placed in direct fluid communication with one another past theupper opening in the valve seat 84.

To close the flush valve assembly 20, the motor 100 or the actuationmember 148 rotates the rotatable valve element 112 such that the one ormore openings in the stationary valve element 116 are covered by therotatable valve element 112 thereby preventing fluid from flowing pastthe stationary valve element 116 (i.e., the relief valve assembly 92 isclosed). After returning to the closed position, the pressure will risein upper chamber 88 as fluid passes through the bypass opening 68 oncefluid communication between upper chamber 88, the outlet passageway 132,and the outlet chamber 136 are shut off. The increased pressure in upperchamber 88 translates the diaphragm assembly 52 back down into a closedposition by pressing the diaphragm assembly 52 against the valve seat84, as shown in FIG. 6. The closed position of the diaphragm assembly 52again, at least temporarily, prevents fluid communication between thelower chamber 44, the peripheral chamber 82, and the outlet chamber 136until the next activation command is given.

The flush valve assembly 20 may be selectively in the open position fora pre-defined or selected period of time and that period of time maydefine a flush cycle. The period of time may be an appropriate amount oftime to generate fluid flow through the flush valve assembly 20 giventhe fixture on which the valve is received such as a urinal or toilet. Anon-limiting example of a period of time range the relief valve assembly92 may be in an open position for may be 0.5 to 3 seconds which mayresult in the flush valve to be open from 3 to 10 seconds. The time therelief valve assembly 92 is selectively in an open position may not bethe time required to complete a flush, as the flush valve assembly 20may be in a closed position while residual fluid may flush.

A flush cycle may be initiated manually or automatically. An automaticflush cycle may occur when the sensor 196 detects a user has approachedthe flush valve assembly 20 and will actuate the cycle when theidentified user has left the flush valve assembly 20. The sensor maycommunicate control instructions to the motor 100 to selectively rotatethe relief valve assembly 92 into the open position in order to initiatea flush cycle. Alternatively, a flush cycle may be initiated manuallyusing the manual actuation assembly 140. A user may use the actuationinterface 144 to initiate a flush cycle where at least a portion of themanual actuation assembly 140 may selectively be actuated into the upperchamber 88 such that fluid communication may be provided between theupper chamber 88 and the actuation passageway 242. The manual actuationassembly 142 may be actuated at the actuation interface 144 which mayextend out a top surface of the upper housing body 22. The manualactuation assembly 142 may initiate a flush cycle in the absence ofpower.

The relief valve assembly 92 is a low-torque implementation of a reliefvalve. The rotatable valve element 112 and the stationary valve element116 may be manufactured, machined, or formed out of a ceramic materialto precise measurements such that a low amount of torque is required torotate the rotatable valve element 112 against the stationary valveelement.

FIG. 9 shows exemplary results for the low torque relief valve asdescribed above and shown in FIGS. 1-8 in which the effect of waterpressure on the torque to operate the valve is illustrated. The reliefvalve assembly 92 may generally function as a pilot valve to initiate aflush cycle as shown, and achieve the torque results depicted in FIG. 9.Generally, the relief valve assembly may require 13.3 ounce-inches(oz-inch) of torque to complete a relief valve cycle, on the high end ofthe test results. One of skill in the art will readily recognize theresults show the relief valve can achieve torque values below 13.3oz-inch. The relief valve cycle includes the rotatable valve element 112being moved from the closed position to the open position and then backto another, different closed position in a single direction of rotationof the rotatable valve element 112. Typical ceramic disc torque data maybe twice or more of these values.

The results further show that the upper limit the relief valve assemblymay require 8.3 oz-inch at 120 psi of fluid pressure versus a typicaltorque of 16 oz-inch of torque to open the relief valve assembly wherethe rotatable valve element 112 is moved from the closed position to theopen position. The relief valve assembly may require less torque toopen, for example, the relief valve assembly may require 2.54 oz-inch oftorque to open. The upper limit the relief valve assembly may require3.3 oz-inch of torque to close where the rotatable valve element 112 isrotated from an open position to a closed position in a single directionof rotation of the rotatable valve element 112. Additionally, the totaltorque that may be required to complete a relief valve cycle may be 11.6oz-inch of torque per cycle, or less. The relief valve assembly mayrequire less torque to close, for example, the relief valve assembly mayrequire 2.32 oz-inch of torque to close.

The low-torque relief valve assembly 92 provides a number of advantagesover relief valves with high torque requirements. The low-torque reliefvalve is impervious to water conditions, presents improved durabilitywith ceramic components, presents low defective parts per millionlevels, and allows for longer battery life due to reduced energyconsumption.

Referring now to FIGS. 10 and 11, a relief valve assembly 392 accordingto another aspect of this disclosure is shown in the flush valveassembly 20. The flush valve assembly 20 is similar to the flush valveof FIGS. 1, 2, and 6-8, but the relief valve assembly 392 in the flushvalve assembly 20 may be the relief valve assembly 392 shown in FIG. 12Aor the relief valve assembly 492 shown in FIGS. 14 and 15.

Accordingly, the flush valve assembly 20 shown in FIG. 10 includes ahousing that includes the upper housing body 22 and the lower housingbody 24 that may be connected such that the upper housing body 22 andlower housing body 24 enclose the flush valve assembly 20. The diaphragmassembly 52 is disposed within the upper housing body 22 and the lowerhousing body 24 between the inlet 28 and the outlet 32 and includes thediaphragm 56 and the disc 60. The flush valve assembly 20 may furtherinclude a manual actuation assembly 140 received in an assembly frame296. The assembly frame 296 may be modified to receive the relief valveassembly 392 at a central location of the assembly frame 296 as opposedto an offset location as shown in FIGS. 1 and 2. A relief valve inlet334 is positioned in the assembly frame 296 that provides fluidcommunication from the upper chamber 88 through the assembly frame 296and into the relief valve assembly 392.

Referring now to FIGS. 12A and 12B, the relief valve assembly 392 may beassembled with the shaft 104 of the motor 100 extending into the drivingmember 408. In some embodiments, a bottom surface of the shaft 104 maybe fixed to a top surface of the driving member 408. In otherembodiments, the shaft 104 and the driving member 408 may be connectedby a keyed connection, D-shape connection, geared connection, or anyother suitable connection between a motor shaft and a driving member.

The driving member 408 may have an upper body extension 452 that extendsradially outward from the driving member 408. The driving memberextension 452 may have curved protrusions 454 that extend outward fromthe upper body extension 452. The curved protrusions 454 may bepositioned at symmetrical locations around a circumference of the upperbody extension 452. The driving member 408 has a driving member body 456that extends downwardly away from the upper body extension 452 into arelief valve housing 420. The driving member body 456 may be cylindricalin shape and extend into contact with the rotatable valve element 412via driving member arms 458 that extend from a bottom surface of thedriving member body 456. As shown, the driving member arms 458 may becylindrical in shape and may be spaced apart on the bottom surface ofthe driving member body 456 such that rotational motion from the motor100 can be translated through the driving member arms 458. Notably, thedriving member 408 may not feature an O-ring seal along the drivingmember 408.

The relief valve housing 420 may be cylindrical in shape having an innerwall 421 and a hollow lower chamber 422. The inner wall 421 extendsradially inward into the relief valve housing 420 to support the drivingmember body 456. The relief valve housing 420 may have an outer surface424 adapted for reception in the assembly frame 296. The hollow lowerchamber 422 receives a valve collar 410 and a rotatable valve element412.

The valve collar 410 is positioned around a top surface of the rotatablevalve element 412, the valve collar 410 and the rotatable valve element412 being received within the relief valve housing 420. The valve collar410 has an opening through a top surface of the valve collar 410 thatallows the driving member body 456 to extend into contact with therotatable valve element 412 via driving member arms 458 that extend fromthe bottom surface of the driving member body 456.

The rotatable valve element 412 may be cylindrical in shape, having atop surface 440 and a mating surface 476. In a non-limiting example, therotatable valve element 412 may have a diameter of 0.456″. The topsurface 440 of the rotatable valve element 412 may have driving memberopenings 444 that are dimensioned to receive the driving member arms 458of the driving member 408. The mating surface 476 of the rotatable valveelement 412 may be axially-facing and mates with a mating surface 484 ofa stationary valve element 416, the respective axially-facing matingsurfaces 476, 484 are in contact with each other. The mating surfaces476, 484 of the rotatable valve element 412 and the stationary valveelement 416 contact each other to form a dynamic seal therebetween thatprevents fluid communication external a flow path through the reliefvalve assembly 392.

The mating surface 476 of the rotatable valve element 412 may have apatterned recess 442 that includes a plurality of channels 446 thatextend outwardly from a centrally-connected location 448. The pluralityof channels 446 may be in fluid communication with one another at thecentrally-connected location 448. As shown, the plurality of channels446 shown includes four channels that extend outwardly from thecentrally-connected location 448 to create a cross-pattern of thepattered recess 442 that may be X-shaped. Accordingly, the patternedrecess 442 may be rotationally symmetrical about a central axis 430 ofthe rotatable valve element 412. The pattered recess 442 may have arecess depth that is less than a thickness of the rotatable valveelement 412. Although a patterned recess 442 is shown as an X-pattern,any appropriate pattern could be used, including symmetrical patternsand asymmetrical patterns.

The stationary valve element 416 may be cylindrical in shape, having themating surface 484 and a bottom surface 486. In a non-limiting example,the stationary valve element 416 may have a diameter of 0.456″. Thestationary valve element 416 may have an inlet opening 490 and an outletopening 488, the inlet opening 490 and the outlet opening 488 extendingthrough the stationary valve element 416 between the bottom surface 486and the mating surface 484. Although an inlet opening 490 and an outletopening 488 are shown, a plurality of inlet openings and a plurality ofoutlet openings could be employed in the stationary valve element 416.The plurality of openings could be arranged in any appropriate pattern,shape, and/or size.

A valve seal 494 is positioned between the stationary valve element 416and the assembly frame 296. The valve seal 494 may have an inlet opening496 and an outlet opening 498 that align with the inlet opening 490 andthe outlet opening 488 of the stationary valve element 416,respectively. The outlet opening 498 may define the valve outlet. Thevalve seal 494 may be cylindrical in shape surrounding each of the inletopening 496 and the outlet opening 498 and can be connected at anintermediate location 500 such that an outer profile of the valve seal494 features a figure-eight shape.

Referring now to FIGS. 14 and 15, another embodiment of the relief valveassembly 492 is shown. The relief valve assembly 492 has many componentsof the relief valve assembly 392. The relief valve assembly 492 has thedriving member 408, the relief valve housing 420, the valve collar 410,and the valve seal 494 described with respect to the relief valveassembly 392. The stationary valve element 516 and the rotatable valveelement 512 differ slightly from the stationary valve element 416 andthe rotatable valve element 512 of the relief valve assembly 392.

The rotatable valve element 512 may be cylindrical in shape, having atop surface 540 and a mating surface 576. In a non-limiting example, therotatable valve element 512 may have a diameter of 0.400″. The topsurface 540 of the rotatable valve element 512 may have driving memberopenings 544 that are dimensioned to receive the driving member arms 458of the driving member 408. The mating surface 576 of the rotatable valveelement 512 may be axially-facing and mates with a mating surface 584 ofa stationary valve element 516, the respective axially-facing matingsurfaces 576, 584 are in contact with each other. The mating surfaces576, 584 of the rotatable valve element 512 and the stationary valveelement 516 contact each other to form a dynamic seal therebetween thatprevents fluid communication external a flow path through the reliefvalve assembly 492.

The mating surface 576 of the rotatable valve element 512 may have apatterned recess 542 that includes a plurality of channels 546 thatextend outwardly from a centrally-connected location 548. The pluralityof channels 546 may be in fluid communication with one another at thecentrally-connected location 548. As shown, the plurality of channels546 shown includes three channels that extend outwardly from thecentrally-connected location 548 to create triangular pattern of thepattered recess 542, each channel being positioned at or approximately120 degrees apart from the other channels. The pattered recess 542 mayhave a recess depth that is less than a thickness of the rotatable valveelement 512. Although a patterned recess 542 is shown as a triangularY-pattern, any appropriate pattern could be used, including symmetricalpatterns and asymmetrical patterns.

The stationary valve element 516 may be cylindrical in shape, having themating surface 584 and a bottom surface 586. In a non-limiting example,the stationary valve element 516 may have a diameter of 0.400″. Thestationary valve element 516 may have an inlet opening 590 and an outletopening 588, the inlet opening 590 and the outlet opening 588 extendingthrough the stationary valve element 516 between the bottom surface 586and the mating surface 584. The mating surface 584 may have a matingrecess 524. The mating recess 524 can be a curved profile that extendsaround the inlet opening 590 that provides fluid communication to agreater area at the mating surface 584. The curved profile of the matingrecess 524 can extend around at any appropriate width and angle.Illustratively, the mating recess curves to an angle less than 180degrees of a diameter of the mating surface 584. An angle of curvatureof the curved profile of the mating recess 584 can similarly be anyappropriate angle, and, as shown, can be approximately 120 degrees. Themating recess 524 can have a depth that is less than a thickness of thestationary valve element 516. Alternatively, the mating recess 524 canextend through the stationary valve element 516, and, accordingly beingone with the inlet opening 590.

Although an inlet opening 590 and an outlet opening 588 are shown, aplurality of inlet openings and a plurality of outlet openings could beemployed in the stationary valve element 516. The plurality of openingscould be arranged in any appropriate pattern, shape, and/or size.Similarly, the mating recess 524 is shown to be connected with the inletopening 590; however, the mating recess 524 can be positioned at theoutlet opening 592.

Now that the components of the relief valve assemblies 392 and 492 theirrespective functionalities can be appreciated. The functionalities ofthe relief valve assemblies 392, 492 will be described with reference tothe flush valve assembly 20. It is to be appreciated that their functionis not limited to use within a flush valve. The use in a flush valve isone example of a use for the relief valve assemblies 392, 492. Therelief valve assemblies 392, 492 could also be used in faucets, plumbingfixtures, mixing valves, and any other appropriate application.

Referring to FIGS. 10-12, 14 and 15, although the relief valve assembly392 and its respective components are labeled, it is to be appreciatedthat the relief valve assembly 492 may be similarly received within theflush valve assembly 20 as shown in FIGS. 10 and 11.

The relief valve inlet 334 is positioned in the assembly frame 296 andprovides fluid communication from the upper chamber 88 through theassembly frame 296 and into the relief valve assembly 392. Fluid iscommunicated from the upper chamber 88 through the valve inlet 334 tothe inlet opening 496 in the valve seal 494 which communicates fluid tothe inlet opening 490 in the stationary valve element 416. The inletopening 490 in the stationary valve element 416 is in selective fluidcommunication with the patterned recess 442 of the rotatable valveelement 412 based on a rotational position of the rotatable valveelement 412 relative to the stationary valve element 416. The rotationalposition of the rotatable valve element 412 may be controlled by thedriving member 456 via the motor 100. The patterned recess 442 on theaxially-facing mating surface 476 selectively places the inlet opening490 and the outlet opening 488 in fluid communication with one anotherbased on a rotational position of the rotatable valve element 412relative to the stationary valve element 416.

In an open position, the inlet opening 490 and the outlet opening 488are placed in fluid communication with one another by the patternedrecess 442 such that the relief valve inlet 334 to the valve outlet 498are placed in fluid communication with one another. In the relief valveassembly 392, the inlet opening 490 and the outlet opening 488 may beselectively aligned at 45 degree incremented positions of the rotatablevalve element 412 due to the angular position of the patterned recess442. The outlet opening 488 is axially aligned with the outletpassageway 132 of the flush valve assembly 20, thereby communicatingfluid to the outlet chamber 136.

In a closed position, the inlet opening 490 and the outlet opening 488are not in fluid communication with one another due to the patternedrecess 442 lacking alignment with the inlet opening 490 therebypreventing fluid communication past the inlet opening 490.

The relief valve assembly 492 operates in a similar manner to the reliefvalve assembly 392. The inlet opening 590 in the stationary valveelement 516 is in selective fluid communication with the patternedrecess 542 of the rotatable valve element 512 based on a rotationalposition of the rotatable valve element 512 relative to the stationaryvalve element 516. The rotational position of the rotatable valveelement 512 may be controlled by the driving member 456 via the motor100. The patterned recess 542 on the axially-facing mating surface 576selectively places the inlet opening 590 and the outlet opening 588 influid communication with one another based on a rotational position ofthe rotatable valve element 512 relative to the stationary valve element516.

In an open position, the inlet opening 590 and the outlet opening 588are placed in fluid communication with one another by the patternedrecess 442 such that the relief valve inlet 334 to the valve outlet 498are placed in fluid communication with one another. In the relief valveassembly 492, the inlet opening 590 and the outlet opening 588 may beselectively aligned at 60 degree incremented positions of the rotatablevalve element 512 due to the angular position of the patterned recess542. In the open position, there may be two points of communication atthe axially-facing mating surfaces 576, 584 between the recess profile542 in the rotatable valve element 412 and the inlet opening 490 and themating recess 524 in the stationary valve element 516.

In a closed position, the inlet opening 590 and the outlet opening 588are not in fluid communication with one another due to the patternedrecess 542 lacking alignment with the inlet opening 590 therebypreventing fluid communication past the inlet opening 590.

The relief valve assemblies 392, 492 may be implemented within the flushvalve assembly 20 as a pilot valve to initiate a flush cycle asdiscussed above with reference to FIGS. 6-8.

The relief valve assemblies 392, 492 are low-torque implementations of arelief valve. The rotatable valve element 412, 512 and the stationaryvalve element 416, 516 may be manufactured, machined, or formed out of aceramic material to precise measurements such that a low amount oftorque is required to rotate the rotatable valve element 412, 512against the stationary valve element 416, 516.

FIG. 13 shows exemplary results for the low torque relief valve assembly392 as described above and shown in FIGS. 10-12. The relief valveassembly 392 may generally function as a pilot valve to initiate a flushcycle as shown, and achieve the torque results depicted in FIG. 13.Generally, the relief valve assembly 392 may require 8.9 ounce-inches(oz-inch) of torque to complete a relief valve cycle, on the high end ofthe test results. One of skill in the art will readily recognize theresults show the relief valve can achieve torque values below 8.9oz-inch. The relief valve cycle includes the rotatable valve element 412being moved from the closed position to the open position and then backto another, different closed position in a single direction of rotationof the rotatable valve element 412.

The results further show that the upper limit the relief valve assemblymay require 5.0 oz-inch of torque to open the relief valve assembly 392where the rotatable valve element 412 is moved from the closed positionto the open position. The relief valve assembly may require less torqueto open, for example, the relief valve assembly may require 3.80 oz-inchof torque to open. The upper limit the relief valve assembly may require3.9 oz-inch of torque to close where the rotatable valve element 412 isrotated from an open position to a closed position in a single directionof rotation of the rotatable valve element 412. The relief valveassembly may require less torque to close, for example, the relief valveassembly may require 3.24 oz-inch of torque to close.

FIG. 16 shows exemplary results for the low torque relief valve assembly492 as described above and shown in FIGS. 14-15. The relief valveassembly 492 may generally function as a pilot valve to initiate a flushcycle as shown, and achieve the torque results depicted in FIG. 16.Generally, the relief valve assembly 492 may require 18.8 ounce-inches(oz-inch) of torque to complete a relief valve cycle, on the high end ofthe test results. One of skill in the art will readily recognize theresults show the relief valve can achieve torque values below 18.8oz-inch. The relief valve cycle includes the rotatable valve element 512being moved from the closed position to the open position and then backto another, different closed position in a single direction of rotationof the rotatable valve element 512.

The results further show that the upper limit the relief valve assemblymay require 9.2 oz-inch of torque to open the relief valve assembly 492where the rotatable valve element 512 is moved from the closed positionto the open position. The relief valve assembly may require less torqueto open, for example, the relief valve assembly may require 4.64 oz-inchof torque to open. The upper limit the relief valve assembly may require9.6 oz-inch of torque to close where the rotatable valve element 512 isrotated from an open position to a closed position in a single directionof rotation of the rotatable valve element 512. The relief valveassembly may require less torque to close, for example, the relief valveassembly may require 3.92 oz-inch of torque to close.

The low-torque relief valve assemblies 392, 492 provide a number ofadvantages over relief valves with high torque requirements. Thelow-torque relief valves retain performance features associated withceramic relief cartridges such as being impervious to water conditions,presenting improved durability with ceramic components, presenting lowdefective parts per million levels, and eliminating drive shaft O-rings.

Referring now to FIGS. 17-20, a valve assembly 692 according to anotheraspect of this disclosure is shown in the flush valve assembly 20. Theflush valve assembly 20 shares similar features to the flush valve ofFIGS. 1, 2, and 6-8. The valve assembly 692; however, as shown, has alower profile than the flush valve assembly 20 as discussed above. Thislow-profile flush valve assembly 20 is achieved by changes in the flushvalve assembly above the upper chamber 88.

Accordingly, the flush valve assembly 20 shown in FIG. 17 includes thelower housing body 24 that may be connected to an upper housing body 622such that the upper housing body 622 and lower housing body 24 enclosethe flush valve assembly 20. The diaphragm assembly 52 is disposedwithin the upper housing body 622 and the lower housing body 24 betweenthe inlet 28 and the outlet 32 and includes the diaphragm 56 and thedisc 60.

An assembly frame 696 may be connected to the bypass extension 120 thatextends downwardly from the assembly frame 696 through the upper chamber88 and into the diaphragm assembly 52. An upper body 628 of the assemblyframe 696 may extend vertically from a lower body 632 of the assemblyframe 696. The upper body 628 of the assembly frame 696 may becylindrical having a hollow inner chamber that defines a top wall of theupper chamber 88. The lower body 632 of the assembly frame 96 may extendradially outward from a bottom surface of the upper body 628 of theassembly frame 696.

A relief valve inlet 534 is positioned in the assembly frame 696 thatprovides fluid communication from the upper chamber 88 through theassembly frame 696 and into a valve frame 698 and into valve assembly692.

The valve frame 698 is connected to a top surface of the upper body 628of the assembly frame 696 at an offset position from the outletpassageway 132 of the flush valve assembly 20. The valve frame 698 mayhave a valve chamber 720 and an actuation chamber 722, each chamber mayhave an a diameter and extend into the valve frame 698 in a directiontransverse to the bypass extension 120 that extends downwardly from theassembly frame 696 through the upper chamber 88 and into the diaphragmassembly 52. In some forms, the diameter of the valve chamber 720 andthe diameter of the actuation chamber 722 may be equal. The valvechamber 720 may receive the valve assembly 692. The actuation chamber722 may receive an actuation assembly 640 that includes an actuationmember 642, a spring 644, and a release element 646.

The valve assembly 692 may have a driving member 708, a rotatable valveelement 712, a stationary valve element 716, and a valve seal 736. Thevalve seal 736 is positioned between the stationary valve element 716and the valve frame 698.

The driving member 708 may be connected to a shaft 704 of a motor 700.The motor 700 may be mounted to a top surface of the upper body 628 ofthe assembly frame 696 in an orientation transverse to the bypassextension 120, and aligned with the valve assembly 692. A driving memberbody 756 may be cylindrical in shape and have radial recesses 658configured to receive one or more O-ring seals 788 between the motor 700and a driving member extension 752. A friction washer 798 may bepositioned against the driving member extension 752 between the drivingmember extension 752 and the radial recesses 658. The driving memberextension 752 extends radially outward from the driving member body 756.

The driving member 708 may further include an inlet opening 742 and anoutlet opening 744. The inlet opening 742 of the driving member 708 maybe positioned on a driving surface 750 that contacts the rotatable valveelement 712. The outlet opening 744 of the driving member 708 may bepositioned on the driving member body 756 between the driving memberextension 752 and the driving surface 750. The inlet opening 742 and theoutlet opening 744 being in constant fluid communication with oneanother. The driving member 708 may have a driving arm 754 positioned onthe driving surface 750, the driving arm 754 engages the rotatable valveelement 712 to selectively rotate the rotatable valve element 712. Thedriving arm 754 may extend a radial location of the driving surface 750such that the driving arm 754 can contact side surface of the rotatablevalve element 712.

The rotatable valve element 712 may be cylindrical in shape, havingopposing flattened driven surfaces 740 and a mating surface 776. In anon-limiting example, the rotatable valve element 712 may have adiameter of 0.250″. The mating surface 776 of the rotatable valveelement 712 may be axially-facing and mates with a mating surface 784 ofa stationary valve element 716, the respective axially-facing matingsurfaces 776, 784 are in contact with each other. The mating surfaces776, 784 of the rotatable valve element 712 and the stationary valveelement 716 contact each other to form a dynamic seal therebetween thatprevents fluid communication external a flow path through the reliefvalve assembly 692. The rotatable valve element 712 may have at leastone opening 772 in fluid communication with the inlet opening 742 of thedriving member 708, the opening 772 being placed at a radial positionfrom the center of the rotatable valve element 712.

The stationary valve element 716 may be cylindrical in shape, having themating surface 784 and an inlet surface 786. In a non-limiting example,the stationary valve element 716 may have a diameter of 0.250″. Thestationary valve element 716 may have an inlet opening 790 extendingthrough the stationary valve element 716 between the inlet surface 786and the mating surface 784. Although an inlet opening 790 is shown, aplurality of inlet openings could be employed in the stationary valveelement 716. The plurality of openings could be arranged in anyappropriate pattern, shape, and/or size.

Fluid is communicated from the valve assembly 692 to the outletpassageway 132 through the assembly frame 696 and the valve chamber 720.The outlet opening 744 in the driving member 708 is connected with anactuation passageway 746 through the valve frame 698, the actuationpassageway 746 is defined between the valve chamber 720 and the outletpassageway 132 and the manual override assembly 640 in the assemblyframe 696. The actuation passageway 746 is in fluid communication withthe outlet passageway 132 through the lower body 128 of the bypassextension 122 of the assembly frame 96. The lower body 128 of the bypassextension 122 is centrally positioned through the diaphragm assembly 52,which connects the actuation passageway 746 with the outlet passageway132.

The relief valve inlet 534 positioned in the assembly frame 696 providesfluid communication from the upper chamber 88 through the assembly frame696 and into the valve assembly 692. In a closed position, the inletopening 790 and the opening 772 are not in fluid communication with oneanother due to the opening 772 lacking alignment with the inlet opening790 thereby preventing fluid communication past the inlet opening 790.

In an open position, fluid is communicated from the valve inlet 534 tothe inlet opening 790 in the stationary valve element 716. The inletopening 790 in the stationary valve element 716 is in selective fluidcommunication with the opening 772 of the rotatable valve element 712that is in fluid communication with the inlet opening 742 of the drivingmember 708 based on a rotational position of the rotatable valve element712 relative to the stationary valve element 716. The rotationalposition of the rotatable valve element 712 may be controlled by thedriving member 708 via the motor 700. Fluid communication is providedthrough the driving member 708 between the inlet opening 742 and theoutlet opening 744. The outlet opening 744 is in fluid communicationwith the actuation passageway 746 which is in fluid communication withthe outlet passageway 132.

The valve assembly 692 may be implemented within the flush valveassembly 20 as a pilot valve to initiate a flush cycle as discussedabove with reference to FIGS. 6-8.

The relief valve assembly 692 are low-torque implementations of a valve.The rotatable valve element 712 and the stationary valve element 716 maybe manufactured, machined, or formed out of a ceramic material toprecise measurements such that a low amount of torque is required torotate the rotatable valve element 712 against the stationary valveelement 716.

FIG. 20 shows exemplary results for the low torque valve assembly 692 asdescribed above and shown in FIGS. 17-19. The relief valve assembly 692may generally function as a pilot valve to initiate a flush cycle asshown, and achieve the torque results depicted in FIG. 20. Generally,the relief valve assembly 692 may require 16.1 ounce-inches (oz-inch) oftorque to complete a relief valve cycle, on the high end of the testresults. One of skill in the art will readily recognize the results showthe relief valve can achieve torque values below 16.1 oz-inch. Therelief valve cycle includes the rotatable valve element 712 being movedfrom the closed position to the open position and then back to another,different closed position in a single direction of rotation of therotatable valve element 712.

The results further show that the upper limit the relief valve assemblymay require 8.2 oz-inch of torque to open the relief valve assembly 692where the rotatable valve element 712 is moved from the closed positionto the open position. The relief valve assembly may require less torqueto open, for example, the relief valve assembly may require 2.90 oz-inchof torque to open. The upper limit the relief valve assembly may require7.9 oz-inch of torque to close where the rotatable valve element 712 isrotated from an open position to a closed position in a single directionof rotation of the rotatable valve element 712. The relief valveassembly may require less torque to close, for example, the relief valveassembly may require 2.84 oz-inch of torque to close.

It should be appreciated that various other modifications and variationsto the preferred embodiments can be made within the spirit and scope ofthe invention. Therefore, the invention should not be limited to thedescribed embodiments. To ascertain the full scope of the invention, thefollowing claims should be referenced.

What is claimed is:
 1. A low-torque valve for regulating fluid flowbetween a valve inlet and a valve outlet, the low-torque valvecomprising: a stationary valve element; a rotatable valve element, thestationary valve element and the rotatable valve element each having arespective axially-facing mating surface in contact with each other andfurther each having at least one opening in which the stationary valveelement and the rotatable valve element are rotationally positionablerelative to one another between an open position and a closed positionthat regulate fluid flow from the valve inlet to the valve outlet basedon an alignment of the openings of the stationary valve element and therotatable valve element; wherein a torque threshold required to rotatethe rotatable valve element into the open position from the closedposition is less than 10 ounce-inches.
 2. The low-torque valve of claim1 further comprising: a valve housing having an internal chamber thatreceives the stationary valve element and the rotatable valve element,the internal chamber having at least one opening in a peripheral wallproviding the valve outlet; an O-ring seal dimensioned to be receivedaround the valve housing configured to form a seal between the valvehousing and a structure into which the valve housing is adapted forreception.
 3. The low-torque valve of claim 2 wherein the at least oneopening in the peripheral wall of the valve housing extends in a radialdirection to accommodate fluid flow in a U-shaped manner up through thevalve elements of the low-torque valve, radially out the at least oneopening in the peripheral wall to bend the flow, and down between anouter radial wall of the valve housing and a structure into which thevalve housing is adapted for reception.
 4. The low-torque valve of claim1 further comprising: the respective axially-facing mating surfaces ofthe stationary valve element and the rotatable valve element contacteach other to form a dynamic seal therebetween.
 5. The low-torque valveof claim 1 wherein a total torque threshold required to complete a valvecycle is less than 12 ounce-inches in which the valve cycle includes therotatable valve element being moved from the closed position to the openposition and then back to another, different closed position in a singledirection of rotation of the rotatable valve element.
 6. The low-torquevalve of claim 1: wherein the at least one opening in the stationaryvalve includes an inlet opening and an outlet opening in which the inletopening is in constant fluid communication with the valve inlet and theoutlet opening is in constant fluid communication with the valve outlet;wherein the rotatable valve element has a patterned recess on theaxially-facing mating surface for selectively placing the inlet openingand the outlet opening in fluid communication with one another based ona rotational position of the rotatable valve element relative to thestationary valve element; wherein in the open position, the inletopening and the outlet opening are placed in fluid communication withone another by the patterned recess such that the valve inlet to thevalve outlet are placed in fluid communication with one another.
 7. Thelow-torque valve of claim 6 wherein patterned recess includes aplurality of channels outwardly extending from a centrally-connectedlocation with the plurality of channels being in fluid communicationwith one another at the centrally-connected location.
 8. The low-torquevalve of claim 7 wherein the patterned recess is rotationallysymmetrical about a central axis of the rotatable valve element.
 9. Thelow-torque valve of claim 6 wherein the inlet openings and the outletopenings are selectively aligned at 60 degree incremented positions ofthe rotatable valve element.
 10. The low-torque valve of claim 6 whereinthe inlet openings and the outlet openings are selectively aligned at 45degree incremented positions of the rotatable valve element.
 11. Thelow-torque valve of claim 6 wherein, in the open position, there are twopoints of communication at the axially-facing mating surfaces betweenthe patterned recess in the rotatable valve element and one of the atleast one openings in the stationary valve element.
 12. The low-torquevalve of claim 1, wherein a total torque threshold required to completea valve cycle is less than 19 ounce-inches.
 13. The low-torque valve ofclaim 1, wherein, a total torque per a valve cycle threshold is lessthan 9 ounce-inches.
 14. The low-torque valve of claim 1, wherein anouter diameter of the stationary valve element and the rotatable valveelement is less than 0.5 inches.
 15. The low-torque valve of claim 1,wherein the rotatable valve element and the stationary valve elementcomprise a ceramic material.
 16. A flush valve assembly comprising: afluid passageway between an assembly inlet and an assembly outlet; achamber positioned along the fluid passageway; a diaphragm assemblypositioned in the chamber and bifurcating the chamber into an upperchamber and a lower chamber in which the diaphragm assembly has adiaphragm having a bypass opening that places the upper chamber and thelower chamber in fluid communication with one another, the diaphragmassembly selectively being received at a diaphragm seat to regulate flowbetween the assembly inlet and the assembly outlet during a flush cycleby controlling fluid communication between the lower chamber and anoutlet chamber that connects the lower chamber to the assembly outlet;the low-torque valve of claim 1, in which low-torque valve is operableas a pilot valve to control a flush cycle by placing the upper chamberand the outlet chamber in selective fluid communication with one anotherso that, when the low-torque valve is in the open position, a fluidpressure from the upper chamber is released through the low-torque valveto unseat the diaphragm assembly from the diaphragm seat to initiate theflush cycle and, when the low-torque valve in the closed position, thediaphragm assembly re-seats on the diaphragm seat due to an increasedfluid pressure on the diaphragm assembly from the upper chamber to endthe flush cycle.
 17. The flush valve assembly of claim 16 wherein thelow-torque valve is axially offset from an axis of the assembly outlet.18. The flush valve assembly of claim 16 wherein a rotational axis ofthe low-torque valve is oriented transverse to the assembly outlet. 19.The flush valve assembly of claim 16 wherein the valve changes thedirection of fluid flow within the valve itself.
 20. The flush valveassembly of claim 16 further comprising: a power source connected to amotor, the motor providing rotational control to the rotatable valveelement to selectively rotate the rotatable valve element into an openposition in which the at least one opening in the rotatable valveelement aligns with the at least one opening in the stationary valveelement thereby providing fluid communication therebetween.
 21. Alow-torque ceramic valve for regulating fluid flow between a valve inletand a valve outlet, the low-torque valve comprising: a stationary discvalve element; a rotatable disc valve element, the stationary disc valveelement and the rotatable disc valve element positioned along a valveaxis and each having a respective axially-facing mating surface incontact with each other, the respective axially-facing mating surfacesof the stationary disc valve element and the rotatable disc valveelement contact each other to form a dynamic seal therebetween thatprevents fluid communication external a flow path through the valve,further the stationary disc valve element and the rotatable disc valveelement each having at least one opening in which the stationary discvalve element and the rotatable disc valve element are rotationallypositionable relative to one another between an open position and aclosed position that regulate fluid flow; a valve housing having aninternal chamber that receives the stationary valve element and therotatable valve element, the internal chamber having at least oneopening in a peripheral wall, the at least one opening in the peripheralwall of the internal chamber provides fluid communication between therotatable valve element and the valve outlet; an O-ring seal dimensionedto be received around the valve housing and dimensioned to prevent fluidcommunication external to a flow path through the valve; wherein atorque threshold required to rotate the rotatable valve element into theopen position is less than 10 ounce-inches.